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Wethering Landy

Member Since: 17 Jun 2022
Location: Suffolk
Posts: 39

2011 Defender 110 Puma 2.4 USW Santorini Black

Inlet Manifold deep clean WOW!

Hi Team Puma

I thought I should share with you my recent discovery of the difference it made when I cleaned the inlet manifold. The engine had snapped a timing chain and so during the replacement of this I decided to give it a bit of TLC. I had always wanted to give it a clean due to the huge black mass that had accumulated on the right hand side of the engine. It was literally thick with gunk.

The engine had always sounded rough - I mean really rough! and especially on start up. It sounded like an old WW2 tank - you probably know what I mean. I also had a lot of black smoke emanating from the exhaust when I put my foot down.

Anyway - on taking the inlet manifold off I was totally shocked beyond belief to find that the inlet ports were almost completely blocked with the blackest sh*t you could possibly imagine. See the images I have attached.
To clean it I used cotton cloths and literally scooped it out. I then used gun wash thinner followed by RTF remover. It took ages and was a really filthy job.

I also cleaned the MAP and MAF sensors. The MAP was filthy.

I decided to then look at the injectors to see if they had been effected - and sure enough - they were covered in filth as well. The seals were shot.

I sent them of to Colchester Fuel Injection Services who tested them and found 2 so badly damaged they needed replacing.

It's a wonder the vehicle was even running.

I fitted new seals on the inlet manifold and sprayed the right hand side of the engine with EGR cleaner and wiped it down with sheets.

I then put it all back together and fired her up. OMG! Its like a new engine. Smooth, powerful and sweet to hear. I would post a video - but I don't know how. I wish I had a before and after. The difference is quite something.

Now I am sure a lot of you will know the culprit here - the dreaded EGR valve. Did I plug it back in? Not a chance!

However this does actually lead me to 2 questions:

1. I now have an engine warning light. How do I get rid?

2. Should I map the injectors to the ECU? It sounds sweet - but maybe they can map out the EGR at the same time??

Thoughts please.

PS.The puma engine is actually fairly bullet proof. I snapped a chain on an engine running on 2 injectors and with inlet ports 50% blocked - and it survived. Not bad really.

15th Jul 2022 4:50pm

Co1

Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 3681

Oh my word! Those pics are ridiculous!!

15th Jul 2022 5:12pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17448

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Those pictures perfectly illustrate the reason why some/many of us have fitted catch cans on the crankcase breather and (shhh!) blank the egr valve. Doing so saves the engine from the ghastly gunge.

15th Jul 2022 6:44pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 531

Thats why my crankcase breathers are rooted to the chassis rails, do more good there.

15th Jul 2022 7:52pm

Wethering Landy

Member Since: 17 Jun 2022
Location: Suffolk
Posts: 39

Crankcase breathers. Now let's talk about these. What exactly are they?

With regards to blanking the EGR - will this allow me to plug it back in and avoid a warning light?
I did read somewhere about someone who removed the gearing from the EGR valve - to trick the system into thinking it was all operating normally. I haven't tried it but it makes sense I suppose.
Has anyone blanked a Puma and got it to work?

Also - re ECU mapping the injectors - is it worth it?

15th Jul 2022 9:37pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17448

The injector codes should be entered into the ECU for optimum performance.

The crankcase breather vents all crankcase fumes from the engine top cover and is plumbed to the air inlet upstream of the turbo so that fumes are reingested and burned. In practice this means a load of stinky air with oil, water, and combustion blow-by in suspension enters the turbo and is then blown to the intercooler and manifold. This is where the black gunge comes from. The best solution is to fit a Provent filter (search the forum for Provent) in the hose from the top cover so the air entering the turbo is clean, thus extending the life of the turbo, intercooler and engine.

The best way to disable the EGR is by means of a software change in the ECU. Most remappers offer this, but be aware it is technically illegal to use a vehicle modified in this way on the road.

15th Jul 2022 10:00pm

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